Standardization and

Interchangeability
Prof. V N A Naikan
IIT Kharagpur
 Standardization
- Market gap or opportunity identification
- Conceptual design
- Detailed technical design
- Parts list: Minimum variety of components, processes, tools.
- As much as possible use all standard parts only
- Non-standard parts only for supporting the main design
- Non-standard parts, in general, should not fail
 Standardization
Standardization is the process of establishing standards or units of
measure by which extent, quality, quantity, value, performance, etc.,
may be compared and measured.
•Standards are the base of mass production
•There are only certain specific sizes made and sold
•Standards are carefully established specification for products,
components and materials
•Standardization produce maximum variety of products using minimum
variety (standardized) of materials, parts, tools and processes
•More economic products
•Easily maintainable
•Non-standard products are only custom made
 Standardization Involves
• Classification
• Coding
Helps easier, accurate, faster, and economic
management of components and parts
during various stages of design,
procurement, manufacturing, marketing,
and service of products.
 Classification
Classification:
• Necessary for NPD
• Grouping items together
by their common features
and subdividing them by
special features.
Bearings
• Ball bearings
• Roller bearings
• Journal bearings
 Classification…
Gears
•Spur Gear
•Helical Gear
•Herringbone Gear
•Bevel Gear
•Hypoid Gear
 Classification…
• Resisters
– Carbon Composition Resistor.
– Thermistor.
– Wire Wound Resistor.
– Metal Film Resistor.
– Carbon Film Resistor.
– Variable Resistor.
– Varistor
– Light Dependent Resistor
 Classification…
• Screws
 Coding
• Using letters and numbers for identifying each
part
• Coding Helps :
– Identify and locate identical items
– Facilitate use of standard items in new designs
– Identify substitutes incase of stock-outs
– Help developing group technology in manufacturing
– To improve parts location in the store
– Computerization requires parts coding
 Example for Coding
Example : IS classifies the grinding wheel as follows.
Grade of Grinding wheel: C54G6U

C 54 G 6 U
    
Silicon Medium Soft dense vetrified
carbide grain size grade structure bond
Abrasive
 Advantages of Standardization
1. Design department
- fewer specification, drawing parts list, less mistakes,
less skill requirement
2. Manufacturing department
- lower unit costs, find easier substitutes, vendor
selection
3. Marketing department
4. Production planning
5. Production control
6. Purchase and stock control
7. Q C
8. Works study
9. Supervision
 Disadvantages

 Reduction in choice
 Changes in public taste may affect sales
immediately
 Difficult to introduce new models with rigid setups
 Helps big companies in mass production scenerio
 Standards once set, difficult to change,
 obstacle to progress!
 International Standards
• ISO  after second W.W. II
• Most industrialized countries are members
• ISO does not issue independent standards of its own but
make recommendations to induce in National standards
• Exporting requires acceptance and implementation of ISO
standards
National Standards
India  IS

UK  BS

Germany  DIN

US  ASO, MIL- STD

 Simplification
- Closely related to standardization
- Reducing the variety of products/components
- Manufacture fewer parts, varieties, and changes
- Removes the superfluous varieties
- Product, assembly, design become less complex & less
difficult
- Lesser confusion
- Availability of suitable standards helps simplification
Some concerns of Simplification
• How simplification will affect customer
demand & volume of sales?
• Does market competition permit
simplification or it encourage products
diversification ?
• More varieties need flexible manufacturing
systems
• Trade off is required
 Advantages of Simplification

- Manufacturing operations simplified

- Quick delivery & better service
- Less inventory
- Fewer parts  less cost, better management
- Better quality
- Product prize reduction
 Specialization
 Standardization & simplification lead to Specialization
 Specialized company: - bearings
- sparks-plugs
 Specialized man power: - produces a small part of a product
- proficient in one activity
- higher skill level is achieved
 Less flexible
 Result in monotony
 Can be applied to: (1) Products
(2) Processes
(3) Individuals
(4) Jobs
(5) Equipment
 Interchangeability
 Great invention of industrial revolution
 Necessary for mass production
 S, S, & S  interchangeability
 Any standardized component will assemble correctly
with any mating standard component both being
chosen at random
 All parts of a given specification must be identical
 Reduces cost - easier assembly - no need of
retrofitting / alterations
 Faster, easier to repair/replacement of parts
 Achieving Interchangeability
- Specify appropriate component tolerances (from
standards) to suit the type of fit required
- Unilateral tolerance
- Bilateral tolerance
- Select manufacturing process to make components within
specified tolerance (Process Capability)
- Inspection & QC must ensure achieving tolerance
- An interchangeable system is also known as a limit
system or a system of limits & fits
 Fits
Kind of engagement between two mating parts
Fits

Clearance Transition Interference

push light shrink or

sliding running driving or
keying force fit
press fit
 Types of Fits
Clearance Fit
When a shaft & journal are assembled a clearance occurs
Largest shaft is smaller than smallest journal

Sliding Fit
 Sliding contact
 Die & punch
 Reciprocating parts

Running Fit
 Shaft on journal bearing
 Types of Fits….
Interference Fit
 Always interference of mating parts
 Diameter of smallest shaft > diameter of biggest hole

Driving or press fit :

 Semi permanent fit
 Need light hammering to assemble
Example : keying a pulley on a shaft

Shrink or Force Fit :

 Permanent fit
 Need great pressure to assemble
Example : Fixing a crank on a locomotive wheel
 Types of Fits….
Transition Fit
~ Between clearance & interference fits
~ When assembled mating parts, either
clearance or interference occurs
Example : smallest shaft could be clearance fit with largest hole &
largest shaft has interference fit with smallest hole
Push fit & Light keying fit
results when assembling is done with the help of light hand
pressure
Example : plugs, fitting dowels/pins in a hole etc
 Allowance
~ the variation given for the purpose of providing different classes of fits
Ex: Hole dimension – shaft dimension
 Shaft basis  keep shaft diameter constant, vary hole diameter
 Hole basis  keep hole diameter constant vary shaft diameter
 modern
 easier  fixed drills of standard diameter are available
 adjusting shaft diameter is easier compared to hole

HL
Shaft IFT
Basic
Hole S
Size
S TF
LL CF
Allowance
End